Effect of Surface Traction and Non-metallic Inclusions on the Premature Failure of Wind Turbine Gearbox Bearings PDF Download

Author: Hamza Abdulrasool Hussain Al-Tameemi
Publisher:
ISBN:
Category :
Languages : en
Pages :

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Author: Thomas Bruce
Publisher:
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Category :
Languages : en
Pages :

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Author: Rui Dai
Publisher:
ISBN:
Category :
Languages : en
Pages : 0

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Author: Leslie R. Rudnick
Publisher: CRC Press
ISBN: 1351655736
Category : Science
Languages : en
Pages : 1770

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Highlighting the major economic and industrial changes in the lubrication industry since the first edition, Synthetics, Mineral Oils, and Bio-Based Lubricants: Chemistry and Technology, Third Edition highlights the major economic and industrial changes in the lubrication industry and outlines the state of the art in each major lubricant application area. Chapters cover the use of lubricant fluids, growth or decline of market areas and applications, potential new applications, production capacities, and regulatory issues, including biodegradability, toxicity, and food production equipment lubrication. The highly-anticipated third edition features new and updated chapters including those on automatic and continuously variable transmission fluids, fluids for food-grade applications, oil-soluble polyalkylene glycols, functional bio-based lubricant base stocks, farnesene-derived polyolefins, estolides, bio-based lubricants from soybean oil, and trends in construction equipment lubrication. Features include: Contains an index of terms, acronyms, and analytical testing methods. Presents the latest conventions for describing upgraded mineral oil base fluids. Considers all the major lubrication areas: engine oils, industrial lubricants, food-grade applications, greases, and space-age applications Includes individual chapters on lubricant applications—such as environmentally friendly, disk drive, and magnetizable fluids—for major market areas around the globe. In a single, unique volume, Synthetics, Mineral Oils, and Bio-Based Lubricants: Chemistry and Technology, Third Edition offers property and performance information of fluids, theoretical and practical background to their current applications, and strong indicators for global market trends that will influence the industry for years to come.

Author:
Publisher:
ISBN:
Category :
Languages : en
Pages : 26

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Wind turbine gearboxes are not always meeting 20-year design life. Premature failure of gearboxes increases cost of energy, turbine downtime, unplanned maintenance, gearbox replacement and rebuild, and increased warranty reserves. The problem is widespread, affects most Original Equipment Manufacturers, and is not caused by manufacturing practices. There is a need to improve gearbox reliability and reduce turbine downtime. The topics of this presentation are: GRC (Gearbox Reliability Collaborative) technical approach; Gearbox failure database; Recorded incidents summary; Top failure modes for bearings; Top failure modes for gears; GRC test gearbox; Bearing nomenclature; Test history; Real damage; Gear sets; Bearings; Observations; and Summary. 5 refs.

Author: Behzad Mahmoudi
Publisher:
ISBN:
Category : Friction materials
Languages : en
Pages : 181

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Spherical roller bearings (SRBs) utilized in the gearboxes of wind turbine generators are known to be especially susceptible to premature failure due to low cycle micropitting of the raceways. Micropitting in rolling element bearings is believed to arise from significant roller/raceway sliding in thin film lubrication conditions. Roller/raceway sliding occurs in SRBs as a consequence of their geometry, and almost all the bearings in wind turbine gearboxes operate in thin film (or low lambda) lubrication conditions. There is currently no accepted solution to mitigate micropitting in wind turbine gearboxes that are equipped with SRBs. Since WC/a-C:H coatings on rolling elements have been effectively used to solve wear issues encountered by SRBs in other industrial applications, these coatings have been offered as a solution to low cycle micropitting in wind turbine gearbox SRBs. This research plan has been developed to test the hypothesis that a WC/a-C:H coating will mitigate or eliminate micropitting such as that experienced by SRBs in wind turbine gearboxes. The laboratory tool that is used to create micropitting on test specimens is the PCS Instruments Micropitting Rig (PCS MPR). The MPR is a three-contact disc machine in which there are three rings of equal diameter positioned at 120 degrees apart with a smaller diameter roller located in the middle and in contact with all the rings. This arrangement allows the test roller to be subjected to a large number of rolling contact cycles in a short period of time and hence significantly reduces testing time. At a typical entrainment speed of 3.5m/s, the central test roller will experience approximately one million contact cycles per hour. Since the controls of the PCS MPR allow the speed, slide-roll ratio, temperature, and load to be automatically and independently controlled, the thin film lubrication and slide/roll ratio conditions that generate micropitting on SRBs can be reproduced in the laboratory. Most wind turbine gearboxes operate with a synthetic ISO-320 lubricating oil with anti-wear and extreme pressure additives. However, to ensure thin film lubrication conditions necessary for micropitting experiments were performed on the MPR using an ISO-10 base oil. Baseline tribological testing were performed using untreated SAE 52100 rings and the roller. The targeted surface finish on the rings and the rollers varied from about 0.2 to about 0.6 micrometer Ra, and the entire surface topography was quantified using a Zygo 7300 3D optical profilometer. The sets of roller and rings were tested on the MPR using a range of slide/roll ratios from 0.0 to +/- 10% at contact stresses up to about 3 GPa. The number of cycles needed to generate the onset of micropitting was recorded and some tests were repeated up to three times. Results of micropitting tests on steel/steel, steel/WC/a-C:H and WC/a-C:H/steel contacts were compared with a tribological conversion coating; black oxide. Black oxide is a surface treatment that converts the surface of ferrous alloys to magnetite (Fe3O4). It has been utilized to reduce wear and corrosion of rolling element bearings and gears, and its use has become especially widespread on roller bearings used in the gearboxes of modular wind turbines. It has been reported that black oxide might have a lower friction coefficient than steel, which may reduce shear stresses due to friction, dampen vibrations, or possibly prevent the diffusion of hydrogen.

Author: Qingkai Han
Publisher: Springer
ISBN: 9811027471
Category : Technology & Engineering
Languages : en
Pages : 168

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This book explores the dynamics and vibration properties of gearboxes, with a focus on geared rotor systems. It discusses mechanical theories, finite-element based simulations, experimental measurements and vibration signal processing techniques. It introduces the vibration-resonance calculation method for the geared rotor system in wind turbines and load sharing of the planetary gear train, and offers a method for calculating the vibrations of geared rotor systems under either internal excitations from gear sets or external loads transferred from wind loads. It also defines and elaborates on parameter optimization for planetary gear systems based on the torsional dynamics of wind-turbine geared rotor systems. Moreover, it describes experimental measurements of vibrations on the wind-turbine gearbox performed on the test rig and on site, and analyzes the vibration signals of different testing points, showing them in both time and frequency domains. Lastly, it lists the gear coupling frequencies and fault characteristic frequencies from the vibrations of the gearbox housing. The technologies and results presented are valuable resources for use in dynamic design, vibration prediction and analysis of gearboxes and geared rotor systems in wind turbines as well as many other machines.

Author: Benjamin J. Gould
Publisher:
ISBN: 9781392010020
Category :
Languages : en
Pages : 224

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Finally, Chapter 10 investigated the effect that a proposed mitigation technique, namely case-carburization, had on the formation of WECs. It is found that employing case-carburization led to a 2.3x elongation in the time until WEC-induced failure.

Author:
Publisher:
ISBN:
Category :
Languages : en
Pages : 0

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A WEC is a particularly aggressive, unpredictable and wide spread rolling element bearing failure mode that is common for large multi-megawatt (MW) wind turbines. WEC is considered the single most expensive failure mode for all wind turbine components, and there is currently no commercial solution. The Technical University of Denmark (DTU) is leading the WhiteWind project to investigate WECs through funding provided by the Innovation Fund Denmark. Other project partners include Vestas, SKF, Expanite, Rheinisch-Westfalische Technische Hochschule Aachen University (RWTH Aachen), and Argonne National Laboratory. The objective of the overall project is to develop a new surface engineered WEC-resistant bearing material using novel surface engineering techniques that shall provide a commercially competitive alternative to existing wind turbine bearings. NREL will support the project by providing existing measured bearing loads and validating models of drivetrain loads.

Author:
Publisher:
ISBN:
Category :
Languages : en
Pages : 0

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Book Description
Wind turbine gearboxes are not always meeting 20-year design life. Premature failure of gearboxes increases cost of energy, turbine downtime, unplanned maintenance, gearbox replacement and rebuild, increased warranty reserves. The problem is widespread and affects most Original Equipment Manufacturers. Not caused by manufacturing practices. Need to improve gearbox reliability and reduce turbinedowntime.